non suzuki swap

[samerrant]

there's a few gearing calculators kicking around you can use. Here's one I like, comes in handy when you don't know what gear ratios are in what tranny, tcase etc...

http://www.grimmjeeper.com/gears.html

As for cruising rpm, I'd say it depends on how your engine is set up, to an extent. I don't think the engine will mind cruising around 3000rpm. Much above that, and, depending on your setup, you'll be more into the boost at cruise, which means fuel economy starts to take a dive.
It's also hard to guess what kind of wind resistance that body will provice compared to a zuk.
Mines much boxier, a 1.9, on 35s, and I still haven't re-geared, so my opinion is probably not even worth the standard 2cents on this one....hopefully you can at least use the gear calculator! 

[zooky]

AAAGGGGHHH! My pictures! They were hosted on off-road's BBS which is now defunct!

Dont worry, they saved the penis enlargement and viagra posts

[zooky]

there's a few gearing calculators kicking around you can use. Here's one I like, comes in handy when you don't know what gear ratios are in what tranny, tcase etc...

http://www.grimmjeeper.com/gears.html

As for cruising rpm, I'd say it depends on how your engine is set up, to an extent. I don't think the engine will mind cruising around 3000rpm. Much above that, and, depending on your setup, you'll be more into the boost at cruise, which means fuel economy starts to take a dive.
It's also hard to guess what kind of wind resistance that body will provice compared to a zuk.
Mines much boxier, a 1.9, on 35s, and I still haven't re-geared, so my opinion is probably not even worth the standard 2cents on this one....hopefully you can at least use the gear calculator! 

I like that calculator!
looks like if I run 29's and use my 4.88's I will be going 77MPH at 3000RPM, that sounds about right.

[zooky]

got the cooling system done today. Its a combination of toyota, VW, volvo and BMW parts. Not much in the way of photos to post but here is one of the overflow tank and the kickdown for the automatic, I made a bracket to mount on the throttle quadrant on the IP. Pretty simple. I got the transmission plumbed and catch can done. Looking around in the junk box (of removed toyota stuff) I found the charcoal canister and remembered that I removed it from where I wanted to mount the catch can. It had a nifty little bracket that worked perfect with a 1qt paint can. That couldnt have been any easier. I got the battery mounted and wired up in the bed and I picked away at the exhaust some more (now with flex pipe). This thing is getting close to being ready to start. I decided to convert to manual steering for now to keep things simple, reduce clutter and keep the load off the engine. I dont think I will need it.

[zooky]

got a bunch more little things done. All the plumbing is done and fluids are topped off (except a little more exhaust work). A buddy swung by and talked me into turning it over to circulate the oil and bleed the IP. Since I got the kit I was concerned (although I am not sure why) about the starter engagement and performance. If anything was off just a bit where was going to be issues, the toyota automatic ACME kit isnt as proven as the sami kit. It ended up cranking perfectly, phew. I really wasnt ready to fire it up, but I admit it would have been nice to hear it run. I cranked it a bit and it never tried to start. I did have the glow plugs disconnected and I was still getting bubbles at the return line. I am hoping thats why it didnt fire off but now am wondering about that? I am hoping that saturday is the day, its suppose to be nice and I want to give myself time to get it running right. I'll report back...

[vwzzuk]

If you bottle feed it until the air pis urged out of the injectors, you'll save some time and wear on your starter. Then after it starts, you can watch your oil pressure and have that big smile when you hear it purrr after it runs out the bubles and equalizes.

[zooky]

WHOO-HOO!
It runs! Fired it up for a few minutes, I have to get it out of the garage so I can run it longer. There was no smoke but the fumes were pretty bad. It was running on jet fuel, I am use to the smell but my wife wasn't impressed. I even popped it in 'drive' but it didn't move, must need more trans fluid. Now I need to figure out how to tune this thing...
It wasn't as diesely sounding as I thought it would be. I got a little turbo whine if I gunned it, I wont get much boost until there is a load on it, yes-no? The engine didn't shake much, less than the 22r I pulled out, that is good some of the clearances are closer then I wanted. I have some loose ends I need to finish up before the maiden voyage. I knew I should have waited until it was done before turning the key, I so want to take it around the block!

[samerrant]

Sweet! Good luck with the test run. And ya, you need to load the engine to get much boost. What turbo are you running?
If it's the stock 1.6 turbo, it'll take a while to spool, apparently boost comes on and it starts to pull around 2500 in the stock vw's...might go a little sooner in a heavier truck.
I'm considering dropping mine in a 4runner some day, so I'm curious how yours does.

[zooky]

the turbo is a K24, just rebuilt. In 'park' I could get 5psi if I floored it, whats a good safe pressure I can run? I'll let you know how it goes, I'd like to do a 4Runner someday too

[samerrant]

If you spend some time on the vw boards, tons of guys running mid 20s. The only issue with the 1.6's and high boost is the head gasket. You can run a metal HG from a 1.9 to get rid of this weak link.

Until then, anything under 20 I'd say would be safe, but there are probably better/more knowledgeable people to ask than me.

[quietmission]

Dude!

Congrats...  You put in a lot of work into this project so i am glad it start working out for you. 
I still have my engine sitting on a pallet and waiting to be gone over.  I am still debating the tracker swap (just wish i could get some help with the engine).
I can't wait for the final test run.

Again well done.

[zooky]

thanks quietmission
I pushed it outside today. I had the block heater plugged in for a few hours so it was nice and warm. I turned the key and after a few seconds it fired right up. After a minute or so the air was bled out of the fuel system and it idled perfect and sounded sweet, not loud and klankity like I expected. I let it idle for 30 minutes. There were no vibes at all, the engine and truck was as smooth as the 22r was. After it was warmed up for awhile I started reving it up, it sounded good and returned right back to idle. Before shutting it down I wanted to rev it good to check the boost. Big mistake. I heard a klunk, I let up on it, and it returned to idle it now has a klunkity sound. Something aint right. Did I wipe out a bearing or something?

[redidbull]

I am still here following the project Randy. Congrats on the success so far with it. Jim

[zooky]

Hey Jim! Glad to see you hanging in there. How are your projects coming along? I think I am getting burnt out, I started these hobbies to relieve stress, not add to them. I think once this is "done" I need to sit back and reevaluate everything.

OK, dropped the pan and checked the bearings. Main bearings are fine. The only thing I found is an indication that the #2 rod bearing spun. The bearing is still in new looking condition but the little tab that sits in that slot is flattened. I am happy I found something but the bearing is still "good" so would losing oil pressure to that bearing cause that noise before the bearing got wiped out? I have to get some new bearings before I can reassemble the bottom end and try it out, its going to drive me nuts in the meantime. Next I guess is popping off the head, dont really want to go there...

[redidbull]

Hey Jim! Glad to see you hanging in there. How are your projects coming along? I think I am getting burnt out, I started these hobbies to relieve stress, not add to them. I think once this is "done" I need to sit back and reevaluate everything.

Randy, I have been gathering parts for the warmer weather. Timing belt and water pump and all that stuff + a small body lift and a few other things. #2 is going to need bodywork and paint. I agree with the burn out. I did a little of that last year and have done it with remodeling projects too. That sit back idea is a good one. Jim